U.S. patent application number 11/057360 was filed with the patent office on 2005-11-17 for modular seating system.
This patent application is currently assigned to United Furniture Industries, Inc.. Invention is credited to Cox, John V., George, Larry W..
Application Number | 20050253430 11/057360 |
Document ID | / |
Family ID | 35308730 |
Filed Date | 2005-11-17 |
United States Patent
Application |
20050253430 |
Kind Code |
A1 |
George, Larry W. ; et
al. |
November 17, 2005 |
Modular seating system
Abstract
A seating system includes several individual seating units that
are coupled together with at least one bracket, where the bracket
extends between two seating units.
Inventors: |
George, Larry W.; (Okolona,
MS) ; Cox, John V.; (Amory, MS) |
Correspondence
Address: |
STEPHEN M. PATTON
7881 GROVE COURT EAST
GERMANTOWN
TN
38138
US
|
Assignee: |
United Furniture Industries,
Inc.
|
Family ID: |
35308730 |
Appl. No.: |
11/057360 |
Filed: |
February 14, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60544464 |
Feb 13, 2004 |
|
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Current U.S.
Class: |
297/248 ;
297/233 |
Current CPC
Class: |
A47C 1/124 20130101;
A47C 13/005 20130101 |
Class at
Publication: |
297/248 ;
297/233 |
International
Class: |
A47C 015/00 |
Claims
We claim:
1. A bracket for a sofa, the sofa comprising a plurality of seating
units, the plurality of seating units including at least one
recliner seating unit and one stationary seating unit coupled
thereto, the reclining unit including a motion unit configured to
rest upon the ground and a seat and a back coupled thereto, and a
stationary unit coupled to the reclining unit, the bracket
comprising: an elongate member having first and second ends, the
member being configured to extend between the motion unit of the
recliner seating unit and the stationary seating unit; a first
coupling disposed at the first end of the member and configured to
be coupled to a first of the plurality of seating units; and a
second coupling disposed at the second end of the member and
configured to be releasably coupled without fasteners to a second
of the plurality of seating units that abuts the first one.
2. The bracket of claim 1, wherein the plurality of seating units
includes three seating units, and further wherein the bracket is
configured to couple only two of the three seating units.
3. The bracket of claim 1, further comprising a vertically
extending member disposed at the second end the vertically
extending member being configured to receive and be coupled to the
second one of the plurality of seating units when the second
seating unit abuts the first seating unit and is slid with respect
to the first seating unit in a direction perpendicular to the
longitudinal extent of the sofa.
4. The bracket of claim 3, wherein the direction perpendicular is
vertical.
5. The bracket of claim 1, wherein the bracket is configured to
prevent relative movement of the second unit with respect to the
first unit both toward and away from the first unit in a direction
parallel to the longitudinal extent of the sofa and to permit
relative movement of the first unit with respect to the second unit
in a direction perpendicular to the longitudinal extent of the
sofa.
6. The bracket of claim 1, further comprising two vertically
extending members that define a space therebetween configured to
receive a frame member of the second seating unit.
7. The bracket of claim 1, wherein the first end of the bracket is
configured to the threadedly fastened to a longitudinal member of
the motion unit.
8. A bracket configured to couple together two adjacent units of
multi-unit upholstered sofa having at least one recliner seating
unit including a motion unit, the bracket comprising: an elongate
member having first and second ends and a length in a direction
perpendicular to the longitudinal extent of the sofa less than the
width of two seating units; a first coupling means disposed at the
first end of the elongate member and configured to couple the
elongate member to a frame of a motion unit; and a second coupling
means disposed at the second end of the elongate member and
configured to couple the elongate member to a frame of a second
seating unit.
9. The bracket of claim 8, wherein the first coupling means is
configured to receive threaded fasteners extending between the
first coupling means and the frame of the motion unit, and wherein
the second coupling means is configured to releasably engage the
frame of the second seating unit.
10. The bracket of claim 9, wherein the second coupling means is
configured to prevent movement of the second seating unit with
respect to the recliner seating unit in a direction parallel to the
longitudinal extent of the sofa and to permit the second seating
unit to be uncoupled from the first seating unit by sliding the
second seating unit with respect to the first seating unit in a
direction perpendicular to the longitudinal extent of the sofa.
11. The bracket of claim 8, further comprising a first vertically
extending surface configured to engage the frame of the second
seating unit, the first vertically extending surface being disposed
perpendicular to a longitudinal extent of the sofa.
12. The bracket of claim 11, further comprising a second vertically
extending surface opposing the first vertically extending surface
and configured to engage the frame of the second seating unit.
13. A bracket for coupling two seating units together, the bracket
comprising: an elongate member having one end configured to couple
to a front-to-rear member of a motion unit; a first vertical member
coupled to the elongate member and configured to engage one surface
of a sidewall of an adjacent seating unit; and a second vertical
member coupled to the elongate member and configured to engage
another surface of the sidewall of an adjacent seating unit.
14. The bracket of claim 13 wherein the first member and the second
member define a gap therebetween that is configured to receive the
sidewall.
15. The bracket of claim 13, wherein the first member is configured
to be coupled to a front-to-rear frame member of the motion
unit.
16. The bracket of claim 13, wherein the first and second vertical
members extend upward from the elongate member.
17. The bracket of claim 13, wherein the elongate member extends
parallel to the ground and adjacent to the ground.
18. A multi-unit sofa, comprising: a first seating unit including a
motion unit configured to recline; a second seating unit; and at
least one bracket extending between and coupling the two seating
units together; wherein the bracket is configured to couple and
uncouple the seating units together without additional
fasteners.
19. The multiunit sofa of claim 18, wherein the bracket is fixed to
the first seating unit and releasably engages the second seating
unit.
20. The multiunit sofa of claim 18, wherein the bracket is fixed to
the motion unit and releasably engages a sidewall of the second
seating unit.
21. The multiunit sofa of claim 18, wherein the second seating unit
is a stationary unit having a vertically extending front-to-rear
sidewall, and further wherein the motion unit includes a
front-to-rear extending frame member configured to rest upon the
ground.
22. The multiunit sofa of claim 18, wherein the bracket extends
between two motion units, and does not extend to a third motion
unit.
23. The multiunit sofa of claim 18, wherein the first seating unit
has an unfinished side, the second seating unit has an unfinished
side, and the bracket holds the two unfinished sides in an abutting
relationship.
24. The multiunit sofa of claim 18, wherein the bracket couples a
side member of the motion unit to a side member of the second
seating unit.
25. The multiunit sofa of claim 18, wherein the first seating unit
has first and second laterally opposing sides, with an integral
armrest disposed at the first side, and the bracket extending from
the second side.
26. A multiunit sofa, comprising: a first seating unit; a second
seating unit; at least a first bracket extending between and
coupling the first and second seating units and not coupling the
third seating unit; a third seating unit; and at least a second
bracket extending between and coupling the second and third seating
units and not coupling the first seating unit.
27. The multiunit sofa of claim 26, wherein the first seating unit
and the third seating unit are motion units.
28. The multiunit sofa of claim 27, wherein the second seating unit
is a stationary seating unit.
29. The multiunit sofa of claim 28, wherein the second seating unit
is disposed between the first and third seating units.
30. The multiunit sofa of claim 26, wherein the first bracket holds
two unfinished sides of the first and second seating units
together.
31. The multiunit sofa of claim 30, wherein the second bracket
holds two unfinished sides of the second and third seating units
together.
32. The multiunit sofa of claim 26, wherein the first bracket is
coupled to a front-to-rear extending member of a motion unit of the
first seating unit at one end and is configured to engage a first
sidewall of the second seating unit.
33. The multiunit sofa of claim 32, wherein the second bracket is
coupled to a front-to-rear extending member of a motion unit of the
second seating unit at one end and is configured to engage a second
sidewall of the second seating unit.
34. The multiunit sofa of claim 26, wherein each of the first
bracket and the second bracket define an open-ended slot extending
generally in a plane perpendicular to the longitudinal extent of
the sofa, wherein the slot supports a member of an adjacent seating
unit.
35. The multiunit sofa of claim 26, wherein the first and second
seating units have a first pair of mutually abutting sides and
wherein the second and third seating units have a second pair of
mutually abutting sides, wherein the first and second seating units
are uncoupled by sliding the first pair of abutting sides with
respect to each other, and wherein the second and third seating
units are in coupled by sliding the second pair of abutting sides
with respect to each other.
36. The multiunit sofa of claim 26, wherein the first, the second,
and the third seating units have removable backs.
37. The multiunit sofa of claim 26, wherein the first, the second,
and the third seating units are configured to be separately
packaged for shipment.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional
Application Ser. No. 60/544,464 to John V. Cox, a co-inventor of
this application, which was filed on Feb. 13, 2004. This
application incorporates herein by reference the 60/544,464
application for all that it teaches.
FIELD OF THE INVENTION
[0002] The invention relates to seating systems. More particularly
it relates to multiple-seat devices such as sofas and modular
seating systems.
BACKGROUND OF THE INVENTION
[0003] There exists a class of furniture made for seating known
generally as "sofas". There are three common ways of constructing
them. This invention is directed to an improved construction for
sofas.
[0004] The first type of sofa has a solid frame, typically wood,
that extends the entire width of the sofa. Fabric and padding are
stretched the length of the sofa to upholster the sofa. The frame
itself is single piece and cannot be broken down or separated into
individual parts without destroying the frame and tearing the
upholstery. The invention below is not directed to sofas with this
traditional construction.
[0005] The second type of sofa is called "modular". It is made of
several individual, freestanding, seating units that are
upholstered on top and on all four sides. Due to this complete
upholstery, each of the seating units can stand alone as an
individual piece of furniture, or alternatively can be placed
adjacent to other seating units. When these modular seating units
are placed in a row, next to each other with abutting upholstered
sidewalls, they look like a sofa. To enhance this appearance, the
upholstered sidewalls are often provided with small couplings such
as snaps, latches or other fixtures that are embedded in the
upholstered sidewalls of the modular units. Snaps on adjacent
abutting upholstered surfaces can be pressed together until they
engage thus holding adjacent modular seating units together and
aligned. When the modular seating units of this second type of sofa
are placed together in abutting relation, it is clear to a casual
observer that the "sofa" is actually a collection of individual and
abutting seating units that could otherwise be used separately. In
other words, a modular sofa looks modular--it looks like a
collection of abutting, freestanding modules.
[0006] Unfortunately, the snaps or latches must be small and
virtually hidden to the outside observer since the upholstered
surfaces on which they are fixed must also be presentable as
upholstered outer surfaces when the modular units are pulled apart.
As a result, these latches are small and have little strength. They
are useful merely to hold adjacent modular units in relative
positions, but are not strong enough to resist being pulled apart
if a user tugs on one of two coupled modular units. The couplings
are also difficult to attach to one another. They are typically
embedded in one or more upholstered sidewalls of each modular unit.
In order to couple two modular units the user must first locate the
small couplings recessed into the fabric, then try to properly
align them by sliding one modular unit back-and-forth with respect
to the other, and then attach them to one another by pressing the
two abutting faces of the two modular units directly against each
other. The user must often press the two modular units together
with considerable force to make the couplings engage each other.
Oftentimes this requires that one modular unit of the two being
attached must be placed against a wall so another seating unit can
be pressed against it with sufficient force. Alternatively, two
people may be required to press the two modular units together with
sufficient force to engage the couplings.
[0007] The third type of sofa is called a "sectional sofa". It does
not have the unitary wooden frame of the first type, nor does it
have multiple individual fully upholstered seating units of the
second type. The third type of sofa was developed about 30 years
ago to combine the reclining function of reclining chairs with
sofas. In this third type of sofa, features of both the first type
and the second type are combined.
[0008] Like the modular sofa, the sectional sofa is made of several
seating units that are coupled together. Unlike the modular sofa,
however, none of the seating units are designed or constructed to
be separated and used individually. Indeed, they cannot be used
individually since each of the seating units of the sectional sofa
has at least one unfinished or semifinished sidewall--in other
words, no sidewall at all, or an un-upholstered sidewall, often
having sharp, exposed edges that would otherwise be a hazard if
they did not abut and be covered by an adjacent seating unit. In
the sectional sofa, these surfaces are unfinished or semifinished
since they are never intended to be exposed once the sofa is
assembled. Traditionally, the individual seating units that
comprise a sectional sofa are assembled at the factory. The seating
units of the third type of sofa are typically semifinished or
unfinished on either one sidewall (in the "arm units" located at
the end of the sofa) or two opposing sidewalls (in the center
seating units located between the two arm units). These unfinished
sidewalls or side surfaces are never intended or designed to be
exposed to view during normal use instead, they are designed to
permanently abut one another when the sofa is assembled and never
be seen. Hence, they do not need to be finished with upholstery or
padding.
[0009] The reason why this third type of sofa is constructed from
several individual seating units (like the second, modular type of
sofa) yet the individual seating units are never intended or
constructed to be used separately (like the first, traditional type
of sofa) is because at least one of the seating units in the
sectional sofa includes a "motion unit". A "motion unit" is a
multi-bar mechanical linkage to which a seat and seat back are
mounted. The motion unit permits the seat and seat back to move
from an upright seating position to a reclining seating position
and back again. Motion units are universally designed to be
freestanding, with the weight transmitted straight down through the
seat back and seat cushion, into the motion unit which is resting
on the floor directly below the seat back and seat cushion that are
reclining. This arrangement is unlike a traditional sofa in which
the weight of a person resting on the sofa is not transmitted down
through mechanical device resting upon the floor, but is
transmitted laterally along the wooden beams forming the frame of
the sofa to short legs at each end of the sofa and to a leg in the
center of the sofa that support the wooden beams.
[0010] In order to appear like a traditional sofa, sectional sofas
use a permanent or semipermanent method of coupling each of their
seating units together. Furthermore, sectional sofas are assembled
at the factory, and are never intended to be disassembled into
their constituent seating units by the end-user. This also
distinguishes them from modular sofas. The seating units of
sectional sofas are assembled and upholstered and finally attached
to one another to form a single large sofa unit at the factory in
which they are made. The seating units (including the recliner
seating units) are attached to one another using two long bars or
channels of steel that are bolted to each seating unit. These long
bars extend the length of the sofa, across all three seating units,
and are the only interconnection between the units--the only thing
that connects all the units together. Once the bars are attached at
the factory to three upside down seating units to form a sofa, the
sofa is inverted to its upright position and is packaged for
shipment in a horizontal position.
[0011] Sectional sofas are prone to damage during shipping, first
because they are quite heavy, and second, because the bars are
unable to properly support the entire sofa without permitting it to
flex or bend when the sofa is lifted at each end. Unlike the long
wooden beams of the traditional sofa, the metal bars of the
sectional sofa are merely intended to hold each of the seating
units in its proper position with respect to the adjacent seating
units. As a result, careless or rough handling of the sectional
sofa can damage it. This is unlike the traditional sofa which has
several long beams extending the entire length of the sofa that are
designed to support the weight of the sofa. When the sectional sofa
is manhandled, the flexing in bending may damage the motion units
and prevent them from operating correctly. Packaging and shipping
sectional sofas made in the traditional manner must therefore be
done quite carefully.
[0012] Packaging and shipping modular sofas, however, is not a
problem, since each individual modular unit is typically wrapped,
packaged, and shipped separate from the other units.
[0013] What is needed, therefore, is an improved seating system or
sofa that permits multi-seat furniture such as sofas to be
transported unpacked, assembled, and later moved around, with
greater ease and less damage. It is one goal of the system
described herein to provide these advantages in one or more
embodiments. What is also needed is a seating system that
eliminates the elongate bars or channels of the prior art to reduce
the weight of the seating system. What is also needed is a process
of manufacturing and shipping seating systems that provides
increased production and manufacturing speed by eliminating the
steps of bolting seating units to an elongate beam and shipping
them in long unwieldy cartons or packages. What is also needed is a
seating system that is lighter in weight than the current sofas.
What is also needed is a method of packaging a sofa in a single
container that can be separated into two or more sub-packages, each
sub-package containing one seating unit to provide for easier
shipping, delivery and installation. It is an object of this
invention to provide the above advantages in one or more
embodiments or aspects of the invention.
SUMMARY OF THE INVENTION
[0014] In accordance with a first aspect of the invention, a
bracket for sofa is provided, the sofa comprising a plurality of
seating units, the plurality of seating units including at least
one recliner seating unit and one stationary seating unit coupled
thereto, the reclining unit including a motion unit configured to
rest upon the ground and a seat and a back coupled thereto, and a
stationary unit coupled to the reclining unit, the bracket
comprising an elongate member having first and second ends, the
member being configured to extend between the motion unit of the
recliner seating unit and the stationary seating unit; a first
coupling disposed at the first end of the member and configured to
be coupled to a first of the plurality of seating units; and a
second coupling disposed at the second end of the member and
configured to be releasably coupled without fasteners to a second
of the plurality of seating units that abuts the first one.
[0015] The plurality of seating units may include three seating
units, and further wherein the bracket may be configured to couple
only two of the three seating units. The bracket may further
include a vertically extending member disposed at the second end,
the vertically extending member being configured to receive and be
coupled to the second one of the plurality of seating units when
the second seating unit abuts the first seating unit and is slid
with respect to the first seating unit in a direction perpendicular
to the longitudinal extent of the sofa. The direction perpendicular
may be vertical. The bracket may be configured to prevent relative
movement of the second unit with respect to the first unit both
toward and away from the first unit in a direction parallel to the
longitudinal extent of the sofa and to permit relative movement of
the first unit with respect to the second unit in a direction
perpendicular to the longitudinal extent of the sofa. The bracket
may further include two vertically extending members that define a
space therebetween configured to receive a frame member of the
second seating unit. The first end of the bracket may be configured
to the threadedly fastened to a longitudinal member of the motion
unit.
[0016] In accordance with a second aspect of the invention, a
bracket configured to couple together two adjacent units of
multi-unit upholstered sofa having at least one recliner seating
unit including a motion unit is provided, the bracket comprising:
an elongate member having first and second ends and a length in a
direction perpendicular to the longitudinal extent of the sofa less
than the width of two seating units; a first coupling means
disposed at the first end of the elongate member and configured to
couple the elongate member to a frame of a motion unit; a second
coupling means disposed at the second end of the elongate member
and configured to couple the elongate member to a frame of a second
seating unit. The first coupling means may be configured to receive
threaded fasteners extending between the first coupling means and
the frame of the motion unit, and wherein the second coupling means
is configured to releasably engage the frame of the second seating
unit. The second coupling means may be configured to prevent
movement of the second seating unit with respect to the recliner
seating unit in a direction parallel to the longitudinal extent of
the sofa and to permit the second seating unit to be uncoupled from
the first seating unit by sliding the second seating unit with
respect to the first seating unit in a direction perpendicular to
the longitudinal extent of the sofa. The bracket may further
include a first vertically extending surface configured to engage
the frame of the second seating unit, the first vertically
extending surface being disposed perpendicular to a longitudinal
extent of the sofa. The bracket may further include a second
vertically extending surface opposing the first vertically
extending surface and configured to engage the frame of the second
seating unit.
[0017] In accordance with a third aspect of the invention, a
bracket for coupling to seating units together is provided, the
bracket including an elongate member having one end configured to
couple to a front-to-rear member of a motion unit; a first vertical
member coupled to the elongate member and configured to engage one
surface of a sidewall of an adjacent seating unit; and a second
vertical member coupled to the elongate member and configured to
engage another surface of the sidewall of an adjacent seating
unit.
[0018] The first member and the second member may define a gap
therebetween that is configured to receive the sidewall. The first
member may be configured to be coupled to a front-to-rear frame
member of the motion unit. The first and second vertical members
may extend upward from the elongate member. The elongate member may
extend parallel to the ground and adjacent to the ground.
[0019] In accordance with a fourth aspect of the invention, a
multi-unit sofa is provided, including a first seating unit
including a motion unit configured to recline; a second seating
unit; and at least one bracket extending between and coupling the
two seating units together; wherein the bracket is configured to
couple and uncouple the seating units together without additional
fasteners.
[0020] The bracket may be fixed to the first seating unit and
releasably engages the second seating unit. The bracket may be
fixed to the motion unit and releasably engages a sidewall of the
second seating unit. The second seating unit may be a stationary
unit having a vertically extending front-to-rear sidewall, and
further wherein the motion unit may include a front-to-rear
extending frame member configured to rest upon the ground. The
bracket may extend between two motion units, and does not extend to
a third motion unit. The first seating unit may have an unfinished
side, the second seating unit has an unfinished side, and the
bracket holds the two unfinished sides in an abutting relationship.
The bracket may couple a side member of the motion unit to a side
member of the second seating unit. The first seating unit may have
first and second laterally opposing sides, with an integral armrest
disposed at the first side, and the bracket extending from the
second side.
[0021] In accordance with a fifth aspect of the invention, a
multiunit sofa is provided, including a first seating unit; a
second seating unit; at least a first bracket extending between and
coupling the first and second seating units and not coupling the
third seating unit; a third seating unit; and at least a second
bracket extending between and coupling the second and third seating
units and not coupling the first seating unit.
[0022] The first seating unit and the third seating unit may be
motion units. The second seating unit may be a stationary seating
unit. The second seating unit may be disposed between the first and
third seating units. The first bracket may hold two unfinished
sides of the first and second seating units together. The second
bracket may hold two unfinished sides of the second and third
seating units together. The first bracket may be coupled to a
front-to-rear extending member of a motion unit of the first
seating unit at one end and is configured to engage a first
sidewall of the second seating unit. The second bracket may be
coupled to a front-to-rear extending member of a motion unit of the
second seating unit at one end and is configured to engage a second
sidewall of the second seating unit. Each of the first bracket and
the second bracket may define an open-ended slot extending
generally in a plane perpendicular to the longitudinal extent of
the sofa, wherein the slot supports a member of an adjacent seating
unit. The first and second seating units may have a first pair of
mutually abutting sides and wherein the second and third seating
units have a second pair of mutually abutting sides, wherein the
first and second seating units are uncoupled by sliding the first
pair of abutting sides with respect to each other, and wherein the
second and third seating units are in coupled by sliding the second
pair of abutting sides with respect to each other. The first, the
second, and the third seating units may have removable backs. The
second, and the third seating units may be configured to be
separately packaged for shipment.
[0023] These and other aspects of the invention will become clear
upon reading the detailed description and viewing the FIGURES
described below, in which like items are numbered alike
throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIGS. 1-4 show a first bracket for connecting individual
seating units to comprise a sofa. The individual seating units
together comprise a sofa.
[0025] FIG. 1 is a side view of the bracket.
[0026] FIG. 2 is a top view of the bracket.
[0027] FIG. 3 is an end view of the bracket.
[0028] FIG. 4 is a view of a metal blank from which the bracket is
formed.
[0029] FIGS. 5-6 are side and top views of a first alternative
bracket for connecting individual seating units to comprise a sofa.
FIG. 5 is a side view of the bracket. FIG. 6 is a top view of the
bracket.
[0030] FIGS. 7-8 are side and top views of a second alternative
bracket for connecting individual seating units to comprise a sofa.
FIG. 7 is a side view of the bracket. FIG. 8 is a top view of the
bracket.
[0031] FIGS. 9-10 are side and top views of a third alternative
bracket for connecting individual seating units to comprise a sofa.
FIG. 9 is a side view of the bracket. FIG. 10 is a top view of the
bracket.
[0032] FIG. 11 is a partial cutaway perspective view of a recliner
seating unit of the sofa uncoupled from its adjacent seating unit
to expose its unfinished side surface and show the interior
construction of the motion unit that permits the seating unit to
recline.
[0033] FIG. 12 is a front view of the three (separated) seating
units that together comprise the sofa, including a first recliner
seating unit with a left arm (i.e. an arm unit), a second recliner
seating unit with a right arm (i.e. a second arm unit), and a
stationary seating unit disposed to be coupled to and between both
of the recliner seating units with any of the brackets of FIGS.
1-10. In this view, the unfinished surfaces of both recliner units
are exposed to show their inner workings. These unfinished side
surfaces of the arm units are pulled away from mating unfinished
surfaces of the central, stationary seating unit).
[0034] FIG. 13 is a front view of the sofa comprised of the three
seating units of FIG. 12 showing the seating units in their
coupled-together configuration in which two brackets extending from
an unfinished side surface of each of the recliner units are
coupled to opposing unfinished side surfaces of the central
stationary seating unit.
[0035] FIG. 14 is a front view of the three seating units
comprising the sofa showing the seating units in their "knocked
down" form substantially as they would appear when removed from
their individual shipping cartons, with exposed unfinished
sides.
[0036] FIG. 15 is a front view of the left arm recliner seating
unit and the central stationary seating unit in the process of
being coupled together.
[0037] FIG. 16 is a perspective view of the left sidewall of the
stationary seating unit showing notches along the lower sidewall
that engage the brackets, prevent them from sliding fore-and-aft,
and maintain the front surface of each of the seating units
coplanar.
[0038] FIG. 17-18 are flowcharts illustrating preferred
manufacturing, packaging, storage, shipping, and assembly processes
for sofas made in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] The term "motion unit" as used herein refers to a steel
multi-bar mechanical linkage having lower support members
configured to rest upon the floor or ground and support the weight
of the motion unit, and brackets that are configured to couple to
and support both a seat back and seat cushion. The support members
and brackets are coupled together to permit the seat cushion and
seat back to move, and therebyto assume several different seating
positions, and to hold the motion unit in each of those seating
positions either by a mechanical lock (also part of the motion
unit) or by frictional engagement of motion unit elements. A motion
unit is not limited to any particular joint or coupling
construction, but may include pivot joints, pin joints, sliding
joints, or other joint arrangements that permit the various bars of
the motion unit to assume their respective positions. A motion unit
may also include a spring or springs to hold the motion unit in a
particular seat cushion and seat back position. The lower support
members of the motion unit are stationary and do not move with
respect to the ground during the reclining process. While it is not
mandatory, it is nonetheless common for motion units to have
fore-and-aft extending members disposed on either side of the
motion unit to which the brackets (described in more detail below)
can be coupled.
[0040] The term "unfinished" as used herein to characterize a
surface, side, or sidewall of a seating unit means that the
surface, side, or sidewall so characterized was not designed or
constructed with the intention of being viewed during normal use.
Seating units with "unfinished" surfaces, sides, or sidewalls are
clearly distinguishable from finished surfaces, sides, or sidewalls
in that they have a raw appearance, are finished with crude fabrics
incompatible with the upholstery fabric, are not finished with any
fabric at all, have exposed wooden or metal edges, have exposed
sharp protrusions, or have labels or instructions applied to the
seating unit or to its packaging indicating that the individual
seating units are not to be used separately. These are just some of
the ways in which a surface, side, or sidewall can be
"unfinished".
[0041] The Bracket
[0042] FIGS. 1-10 disclose alternative embodiments of a bracket 100
that is provided to couple individual seating units together to
form a sofa. FIGS. 1-4 disclose a first embodiment of bracket 100.
The embodiment of FIGS. 1-4 has an elongate member 102. Three
braces 104, 106, 108 are coupled to member 102 and extend upward
therefrom. Braces 104, 106 extend upward from elongate member 102
and have a first surface 109 that is configured to engage an outer
surface 110 of a sidewall 112 (here shown in phantom lines) of a
seating unit 114. Brace 108 extends upward from elongate member 102
and has a first surface 115 that faces surface 109 and is
configured to engage an inner surface 116 of sidewall 112.
[0043] Bracket 100 is formed of a single piece of planar steel,
preferably 0.125 inches thick. It is preferable that the entire
bracket be between 0.09 and 0.20 inches thick. The bracket is
preferably stamped or punched out of steel ribbon or coil stock to
form a blank that is subsequently bent to form braces 104, 106, and
108. Bracket 100 preferably has an overall width W of between 1 and
4 inches, and more preferably between 1.5 and 2.5 inches, and even
more preferably 2 inches. Bracket 100 preferably has an overall
height H of between 1 and 4 inches, more preferably between 1.5 and
3.5 inches, and even more preferred is between 2 and 3 inches in
height.
[0044] Elongate member 102 and braces 104, 106, and 108 are
generally flat and have a constant thickness. Brace 108 extends
upward from elongate member 102 above the top of braces bold on
104, 106. Braces 104, 106 are therefore shorter (FIG. 1) than brace
108.
[0045] Several holes are provided in bracket 100 that permit the
bracket to be fixed to the seating units of the modular furniture.
In particular, member 102 has two holes 118 that are configured to
receive fasteners 120 extending between member 102 and lower
support member 156 of motion unit 122 of recliner seating unit 124.
A hole 126 is also provided in brace 108 to permit the operator to
fix bracket 100 to sidewall 112 of seating unit 114 with screw
128.
[0046] The function of bracket 100 is to couple two adjacent
seating units together. Lower support member 122 in FIG. 1 is a
portion of one seating unit. Seating unit 114 is an adjacent
seating unit. These two seating units are coupled together (better
shown in FIGS. 13-16) by brackets 100, which are coupled to lower
support members of the motion unit of one seating unit 124 at one
end and are coupled to a sidewall 112 of an adjacent seating unit
114 at the other end, thereby coupling them together. As will be
explained below, two brackets are preferably used to couple two
adjacent seating units together.
[0047] Facing surfaces 109 and 115 of bracket 100 are parallel and
spaced equidistantly apart. They define therebetween a slot or gap
117 that receives sidewall 112 of seating unit 114. This slot or
gap preferably has a constant width slightly larger than the width
of sidewall 112. This arrangement permits the two adjacent seating
units 114, 124 to be attached to one another simply by raising
seating unit 114 slightly, positioning slot 117 of bracket 100
underneath it, and lowering seating unit 114 until sidewall 112 is
located in slot 117. Sidewall 112 is shown (in dashed lines)
located in slot 117 in FIGS. 1 and 11.
[0048] Once they are coupled together with bracket 100, the seating
units can be held together even more securely (if desired) by
inserting screw 128 through hole 126 and into sidewall 112. Screw
128 fixes sidewall 112 to bracket 100, preventing sidewall 112 from
being lifted up and out of slot 117.
[0049] FIG. 4 illustrates a steel blank or stamping 130 that has
been punched out of steel ribbon or coil stock as a preliminary
step to forming bracket 100 of FIGS. 1-3. Blank 130 is bent to form
braces 104, 106, 108 of bracket 100 in subsequent manufacturing
operations. The lines along which these bins are made to blank 118
are shown as dashed lines in FIG. 4. In an alternative
manufacturing process, bracket 100 is formed from ribbon, or strip
stock in a series of progressive dies that successively form the
outlines of bracket 100 (as shown in FIG. 4) and bend braces 104,
106, 108.
[0050] The bracket embodiment shown in FIGS. 1-4 is preferred.
Alternative embodiments may be used in place of the embodiment
shown in FIGS. 1-4, however. Samples of several alternative
embodiments are shown in FIGS. 5-10.
[0051] A first alternative embodiment of bracket 100 is shown in
FIGS. 5-6. In FIGS. 5-6, bracket 100 is formed out of a length of
steel 131 that is bent in three places 132, 134, 136 to form an
elongate member 102 from which braces 104, 108 extend upward. This
embodiment has the same overall width, overall height, and overall
length as the embodiment of FIGS. 1-4. It also has the same
mounting holes 118 and securing hole 126 as the embodiment shown in
FIGS. 1-4. The gap between braces 104 and 106 in FIGS. 5-6 is the
same as the gap 117 between braces 104, 106, and 108 in the
embodiment of FIGS. 1-4. The only difference between the embodiment
of FIGS. 1-4 and the embodiment of FIGS. 5-6 is the way in which
the metal is bent to form the elongate member 102 and braces 104,
108 from steel strip or roll stock.
[0052] An advantage to the bracket embodiment of FIGS. 5-6 is that
it can be formed from a single strip of steel stock merely by
cutting a length of the stock off and bending it in three places.
The additional steps of punching out separate side braces (see e.g.
FIG. 4) is eliminated.
[0053] Yet another embodiment of bracket 100 is shown in FIGS. 7-8.
This embodiment also has the same overall height, overall width,
and spacing between its two braces 104, 108 as the embodiment of
FIGS. 1-4. The embodiment of FIGS. 7-8 is formed of two pieces of
steel strip or ribbon stock that are welded together to form an
elongate member 102 from which to upwardly extending braces 104,
108 extend. In this embodiment, brace 104 is welded to member 102.
To construct this embodiment, two strips of steel stock are
required. And "L"-shaped bend 140 is formed in a longer piece 138
to define brace 108 and elongate member 102. The second strip of
steel stock 142 is welded to member 102 and extends upwardly
therefrom to form brace 104.
[0054] A further embodiment of bracket 100 is shown in FIGS. 9-10.
This embodiment also has the same overall height, overall width,
and spacing between its two braces 104, 108 as the embodiment of
FIGS. 1-4. The embodiment of FIGS. 9-10 is formed of two pieces of
steel strip or ribbon stock to define an elongate member 102 from
which two upwardly extending braces 104, 108 extend. These two
pieces of steel are fixed together with threaded fasteners 148.
Alternatively, they can be riveted or welded together.
[0055] Each of the above embodiments provides a gap configured to
receives sidewall 112 in the same place as gap 117 in the
embodiment of FIGS. 1-4.
[0056] Brace 104 in FIGS. 9-10 is a portion of an "L"-shaped member
146 that is fixed to elongate member 102. Member 146 is fixed to
member 102 by threaded fasteners 148 which extend through holes in
both member 102 and member 146. An advantage of this design is that
it permits adjustment of the slot or gap between braces 104 and
108. As in all the previous examples, the overall width, the
overall height, and spacing between braces 104 and 108 are the same
as in the embodiment of FIGS. 1-4.
[0057] Seating Units
[0058] FIG. 11 illustrates recliner seating unit 124 to which two
brackets 100 have been fixed by fasteners 120. Seating unit 124
includes a motion unit 122 that includes a rectangular frame 150
comprised of two laterally extending lower support members 152, 154
that extend across the front and rear, respectively, of the motion
unit. Frame 150 is also comprised of two front-to-rear extending
members 156, 158 that are fixed to opposite ends of members 152,
154. These four members 152, 154, 156, 158 are fixed together at
right angles to one another to define a rectangular box frame that
rests upon the ground. Motion unit 122 further includes bars 164,
which are pivotally coupled to each other to form a multi-bar
linkage. Bars 164 are pivotally coupled to a flange 162 extending
upward from frame member 156.
[0059] Brackets 100 are fixed to front-to-rear member 156, one
forward of the other. The brackets are oriented with respect to
each other such that gaps 117 of both brackets are aligned to
receive a single sidewall frame member 112 of adjacent stationary
seating unit 114. This frame member is shown in dashed line form in
FIG. 11 as a rectangular beam extending both vertically and
front-to-rear. The other portions of stationary seating unit 114
have been removed for ease of illustration.
[0060] Brackets 100 are of identical length. They orient sidewall
112 in a front-to-rear orientation with respect to seating unit 124
and hold it parallel or generally parallel to the side 160 of
seating unit 124.
[0061] To insert sidewall 112 into position in brackets 100, the
user moves it to side 160 of seating unit 124 in a generally
abutting side-to-side relationship, and then lowers it (moves it
vertically downward) until the sidewall 112 is held firmly in the
gap or slot defined between braces 104, 106, and brace 108 of each
of the brackets 100. This process is illustrated in FIG. 15. The
bottom surface of sidewall 112 preferably does not touch the bottom
of the gap or slot 117. It preferably is positioned slightly above
the bottom (e.g. slightly above the top of elongate member 102). In
this manner, bracket 100 does not hold sidewall 112 and hence the
side of seating unit 114 up in the air, and sidewall 112 does not
bend bracket 100 downward if the seating units are resting on
uneven ground. The weight of seating unit 112 rests upon its frame
members, which in turn rest upon the ground.
[0062] To remove sidewall 112 and seating unit 114 from bracket
100, the process is reversed: sidewall 112 is lifted vertically
upward until it clears brace 108, at which point sidewall 112 (and
seating unit 114 of which it is a part) can be moved laterally away
from seating unit 124. The direction that unit 114 must be moved
with respect to unit 124 so bracket 100 can clear sidewall 112 is
perpendicular to the longitudinal extent or lengthwise direction
("L" in FIG. 13) of the sofa.
[0063] When sidewall 112 is inserted into the gaps or slots 117 of
brackets 100, sidewall 112 is prevented from moving both toward and
away from recliner seating unit 124. Brackets 100 are fixed such
that the facing inner surfaces of braces 104, 106, 108 are oriented
perpendicular to the side-to-side extent of seating unit 114 and
124. When all three seating units are coupled together (FIG. 13) to
form a complete sofa, the side-to-side direction is parallel to the
longitudinal extent or lengthwise direction of the sofa. Thus,
brackets 100 prevent adjacent seating units from moving toward or
away from one another in a direction parallel to the length ("L" in
FIG. 13) of the sofa.
[0064] This arrangement of brackets 100 permits the seating units
of the sofa to be easily separated merely by lifting one or more of
the units with respect to the other and sliding the lifted unit
away from its adjacent unit. At the same time, once all three
seating units of the sofa are coupled together (as shown in FIG.
13) the user can grab either end of the sofa, push it, pull it, or
otherwise slide it across the floor on which it rests to reposition
the entire sofa. A single user can, for example, pull the entire
sofa away from a wall to permit cleaning behind the sofa by
grasping an armrest at one end of the sofa and pulling the end unit
having the armrest away from the wall. The other units, due to the
superior strength and configuration of brackets 100, are
constrained to remain in their predetermined relative positions
with respect to the unit on which the user pushes and pulls.
[0065] This ability to be pushed, pulled, and dragged around a room
without tearing the individual units apart is lacking in the
traditional modular sofas. Modular sofas, with their small snaps or
other retaining devices embedded in upholstered surfaces, are
unable to withstand such pushing and pulling without being pulled
apart. Furthermore, the snaps are attached to the fabric of the
modular units, and not to hard physical structures such as the
frame of the stationary unit or elongate members of the motion
unit. The connectors coupling seating units of modular sofas are
operated by abutting two modular units and pressing them against
each other in a direction perpendicular to the plane of their
abutting surfaces--i.e. parallel to the longitudinal extent of the
modular sofa. The connectors between seating units of modular sofas
are also frictional-type connectors that do not positively lock. If
enough forces applied to the connectors are snaps between modular
units, they are intended to uncouple and pull apart. Modular unit
connectors are typically industrial snap fasteners. In contrast to
this, sofas using bracket 100 are engaged and disengaged from one
another by lifting or lowering one seating unit with respect to the
other, by sliding the surface of one seating unit with respect to
the surface on the adjacent seating unit that it abuts. Pushing or
pulling a seating unit according to the present invention, such as
by sliding a sofa around and repositioning it on the floor will not
cause brackets 100 to become disengaged. Brackets 100 positively
lock. They will not release when pulled in a direction
perpendicular to the surfaces on a joining seating units that they
hold together.
[0066] Recliner seating unit 124 includes several further
components in addition to frame 150 of motion unit 122 and brackets
100. Each of the front-to-rear of members 156, 158 includes a
vertically extending flange 162 to which several bars 164 of a
multi-bar linkage are pivotally coupled. FIG. 11 only illustrates
the multi-bar linkage that is pivotally fixed to and extends upward
from front-to-rear member 156. Motion unit 122 includes an
identical multi-bar linkage (but in mirror image form) is fixed to
and extends upward from a similar flange lawn front-to-rear member
158 located on the other side of seating unit 124. These two
multi-bar linkages are typically coupled together to synchronize
their movements. Each of the two multi-bar linkages includes a
member 172 to which the seat back 170 is coupled.
[0067] The particular arrangement of these bars is beyond the scope
of this invention and is not described herein. Each manufacturer of
motion units has its own preferred configuration of bars 164 that
provide what that manufacturer believes to be the most pleasing
motion for reclining the recliner seating unit.
[0068] Recliner seating unit 124 also includes an upholstered seat
166 that is fixed to the top of the two multi-bar linkages disposed
on both sides of (and extending upward from both sides of) the
motion unit base. Seat 166 is typically screwed on to upper
portions of the multi-bar linkages such that seat 166 can only be
removed by reaching underneath the seat and unscrewing it.
[0069] Recliner seating unit 124 also includes an upholstered
footrest 168 that is fixed to forward portions of the multi-bar
linkages. The multi-bar linkages are configured to pivot footrest
168 upward and outward away from seat 166 when motion unit 122 is
reclined to thereby support the user's ankles and feet.
[0070] Recliner seating unit 124 further includes an upholstered
seat back 170 which is removably fixed to two pivoting members 172
of the two multi-bar linkages that extend upward from the rear top
portions of the multi-bar linkages. Seat back 170 has two
corresponding sockets 174 fixed to a lower portion of the frame of
seat back 170 on either side of seat back 170 that are configured
to receive members 172. Seat back 170 is fixed to motion unit 122
only by these two members 172. This provides a quick connect
between the seat back 170 and the motion unit itself. By pulling
sharply upward on the seat back, the user can disconnect the seat
back from the motion unit and lay it flat for shipment. Similarly,
by pressing sharply downward on the seat back, the operator can
coupled the seat back to the motion unit without additional
fasteners (unless additional security is desired).
[0071] Motion unit 122, when operated, pivots members 172 backward,
causing the seat back 170 to recline. At the same time, motion unit
122 causes seat 166 to translate forward and the rear portion of
seat 166 to move slightly downward. At the same time, motion unit
122 causes foot rest 168 to pivot upward and outward away from seat
166 to a position in which it can support the user's legs. Each of
the three components--the foot rest, the seat, and the seat
back--are fixed directly to bars of both the multi-bar linkages
pivotally coupled to and extending upward from the front-to-rear
frame members 156, 158.
[0072] The upholstered seating unit may include alternative
structures designed to increase its usability. For example, a
seating unit may be a console unit, which comprises one or more of
a variety of other structures such as an armrest, a drink holder, a
pocket for receiving remote controls and the like, a cooler or
refrigeration unit, or a box. Console units may be as wide as a
regular seating unit designed for seating, or they may be
significantly narrower, for example 8-12 inches wide.
[0073] The Sofa
[0074] FIGS. 12-14 illustrate a multi-unit sofa 177 comprised of
three seating units, including a recliner seating unit 124, a
stationary unit 114 and a second recliner unit 175. FIG. 12 shows
the three seating units separated, but disposed adjacent to one
another as they would appear when coupled together. FIG. 13 shows
the three seating units assembled to form sofa 177. FIG. 14 shows
the three seating units adjacent one another with their seat backs
removed and placed on top of their seats. This shows the seating
units as they would appear immediately after removal from their
separate shipping boxes or cartons, or just prior to being inserted
into their separate shipping boxes or cartons.
[0075] Referring now to FIG. 12, the two recliner seating units
124, 175 are disposed on either side of stationary seating unit
114. Recliner seating unit 124 is described above in conjunction
with FIGS. 1-11. Stationary seating unit 114 is also described
above with regard to FIG. 1 and FIG. 11 and below with regard to
FIG. 16.
[0076] Recliner seating unit 175 is an identical, mirror image of
recliner seating unit 124 and is disposed on the opposite side of
stationary seating unit 114. Recliner seating unit 175 engages
corresponding adjacent and abutting sidewall 176 of stationary unit
114 in a manner identical to the way recliner seating unit 124
engages sidewall 112 of stationary unit 114. Just as brackets 100
on recliner seating unit 124 engage sidewall 112, so do brackets
100 on recliner seating unit 175 engage sidewall 176. Recliner
seating units 124, 175 are mirrored with respect or each other
about a mirror plane that extends perpendicular to the longitudinal
extent of the sofa (i.e. direction "L" in FIG. 13) and extending
through the middle of stationary unit 114. This mirror relationship
can be seen best in FIG. 12 and FIG. 13.
[0077] Each recliner seating unit has an armrest 177 that is
disposed at its outermost edge. The recliner seating units have
only a single unfinished or semifinished side. Each unfinished side
faces and couples to an adjacent unfinished side of seating unit
114. The opposing finished side surface on each recliner seating
unit defines the end side wall of the sofa. It is not configured to
be coupled to any adjacent seating unit. It is upholstered and
finished in the same manner as the other exposed surfaces of the
sofa.
[0078] Stationary seating unit 114 has a box frame construction and
no motion unit. The left side of seating unit 114 (as shown in FIG.
12) has a front-to-rear extending sidewall 112 that defines the
leftmost edge of seating unit 114. Similarly, the right side of
seating unit 114 (as shown in FIG. 12) has a front-to-rear
extending sidewall 176 that is configured to engage brackets 100 of
seating unit 175. Sidewalls 112 and 176 extend vertically from the
ground upward for approximately 10 inches. When the sofa is
assembled, the sidewalls 112, 176 are coupled to brackets 100 on
recliner seating units 124 and 175 to make the single integrated
multi-unit sofa that is best shown in FIG. 13.
[0079] Stationary seating unit 114 is formed in two portions. The
first portion is a lower seat portion 178 which includes an
upholstered seat as well as the box frame (including sidewalls 112,
176) that support it. Lower seat portion 178 rests upon the ground.
The second portion is a seat back 180 removably coupled to lower
seat portion 178. Lower seat portion 178 has upwardly extending
members fixed to the rear corners of its box frame that extend
upward therefrom. These members cannot be seen in FIG. 12. They
are, however, constructed and positioned identical to members 172
of the seating unit 124. Unlike members 172 of seating unit 124,
however, the members at the rear corner of the box frame are not a
portion of a motion unit. They are fixed directly to the box frame
of lower seating portion 178. These members are inserted into
sockets fixed to either side of the bottom of seat back 180. These
sockets are constructed and positioned identical to sockets 174 on
seat back 170 of motion unit 124. Because of this member and socket
coupling structure, seat back 180 can be separated from lower seat
portion 178 by lifting seat back 180 upward, thereby disconnecting
the seat back from lower seat portion 178. The seat backs 170 of
motion units 124 and 175 are removable in the same manner. By
providing for the easy removal of the seat backs of all three
seating units in this manner, each of the three seating units can
be packed into a much smaller space for shipping and storage.
[0080] FIG. 14 illustrates the three seating units in their
"knocked down" (i.e. disassembled for shipping and storage) state.
FIG. 14 illustrates the orientation of each of the three seating
units with their surrounding packaging removed. FIG. 14 shows the
three units as they are packed for shipping. In FIG. 14, the seat
backs are placed directly on their corresponding seat portions with
the upholstered and padded side of the seat back (i.e. the portion
against which the user rests his back) facing downward. The seat
backs are disposed generally horizontally in FIG. 14. This reduces
the overall height of each seating unit. In this manner, each of
the seating units takes up a minimal amount of space. Further, this
arrangement creates a broad flat upper surface (i.e. the back
surface 190 of each of the seat backs) that distributes any load
placed on top of the seating unit evenly to the lower portion of
the seating unit. This broad load distribution permits the three
seating units to be stacked one atop the other for shipping. Each
of the seating units is placed inside its own individual shipping
container (for example, cardboard, paperboard, or corrugated
paperboard boxes).
[0081] FIG. 15 illustrates the manner in which the individual
seating units are coupled together. To assemble the knocked down
seating unit shown in FIG. 14 the user first attaches each seat
back to its respective seat portion. The operator lifts the seat
backs off their respective seat portions, raises them into a
substantially vertical position and presses them and their sockets
174 downward on to the corresponding mating members extending
upward from the back of the seat portions.
[0082] Once the seating units are assembled, the user grasps one of
the units (in the example shown in FIG. 15, seating unit 114),
moves that unit into a position adjacent to the seating unit to
which it shall be attached (e.g. adjacent to seating unit 124),
slides an abutting side surface 192 upward with respect to an
abutting side surface 194 of the adjacent seating unit (e.g. unit
124), then slides side surface 192 downward until brackets 100 (not
shown in FIG. 15) engage sidewall 112 of seating unit 114. If the
user wishes the seating units to be more securely fastened
together, the user can insert screws 128 through brackets 100 and
screw them into sidewall 112.
[0083] FIG. 15 only illustrates two seating units 114, 124. Seating
unit 175, while not separately illustrated, is attached to the
opposite sidewall 176 of seating unit 114 in a manner identical to
that of seating unit 124. The user slides seating unit 175 until it
is adjacent to the opposing side surface 196 of seating unit 114.
The surface is identical to surface 192 but is on the opposite side
of seating unit 114. Once seating unit 175 is in this position, the
user lifts seating unit 114 upward slightly, then pushes the side
surface of seating unit 175 into an abutting relationship with side
surface 196. Once in this position, the operator lowers seating
unit 114, letting sidewall 176 slide downward into slots 117 of
brackets 100 that extend from seating unit 175. This process of
attaching seating unit 175 to seating unit 114 is identical to the
process followed in attaching seating unit 124 to seating unit 114.
As in the case of attaching seating unit 124 to seating unit 114,
the user can insert screws 128 through brackets 100 and into
sidewall 176 once seating units 175 and 114 are coupled together as
described above.
[0084] Disassembly of the sofa into its three individual seating
units follows the reverse process. First, any screws 128 are
removed. Second, seating unit 114 is lifted upward, sliding side
surfaces 192, 196 of unit 114 along the mating surfaces 194, 198 of
units 124, 175, respectively, until brackets 100 on both unit 124
and unit 175 are clear of sidewalls 112, 176. At this point, unit
114 can be simply set aside, or units 124 and 175 can be withdrawn
away from unit 114 and unit 114 lowered back to the ground. Either
method will separate the assembled sofa into three separate
units.
[0085] It should be clear from this description that in order to
couple the seating units together, the seating units are moved
relative to one another in a direction generally perpendicular to
the longitudinal extent of the sofa.
[0086] Unit 114 may be translated vertically to either couple it
to, or uncouple it from, the other two seating units. It can also
be pivoted or tilted about a front-to-rear axis, as shown in FIG.
15, to slide its side surfaces 192, 196 upward and away from
brackets 100. Alternatively, it can be pivoted backward about its
side-to-side extending back bottom edge 200 (FIG. 16) or pivoted
forward about its side-to-side extending front bottom edge 202
(FIG. 16). Whether tilted side-to-side about a front-to-rear axis
as shown in FIG. 15, or tilted forward about its front bottom edge
202, or backward about its back bottom edge 200 as shown in FIG.
16, the effect is the same: the side surfaces 192, 196 of seating
unit 114 are translated in a plane perpendicular to the
longitudinal extent (i.e. the direction of length "L" in FIG. 13)
until the seating units are coupled or uncoupled.
[0087] FIG. 16 shows features of stationary seating unit 114 that
contribute to holding the three seating units in proper
front-to-rear alignment with respect to each other. Brackets 100
engage slots at the bottom edges of the sidewalls of seating units
114 to hold the three seating units in proper front-to-rear
alignment, such that front surfaces 204, 206, 208 of seating units
124, 114, 175 are co-planar, extend straight across the front of
the sofa. This eliminates substantially all front-to-rear free play
between brackets 100 and the sidewalls of seating unit 114 that
might otherwise let one of the seating units slide forward or
backward with respect to the other seating units. This
straight-line, coplanar orientation is best shown in FIG. 13.
Seating unit 114 is configured to engage brackets 100, holding them
in the proper front-to-rear position, aligning the front surfaces
of all three seating units co-planar as shown in FIG. 16. Slots or
recesses 210 are located on the bottom edge 212 of both the lateral
sidewalls 112, 176 of seating unit 114. Only sidewall 112 is
illustrated in FIG. 16. Sidewall 176 and its slots are configured
identically to sidewall 112 and its slots 210 but in mirrored form.
The depth of the slots 210 in the sidewalls are sufficient to
receive elongate members 102 of brackets 100, and to provide a
slight clearance between brackets 100 and the ground. The bottom of
slots 210 does not touch and is not supported by brackets 100. The
preferred distance between the ground and top 212 of slots 210 is
between 0.3 and 1.5 inches. Slots 210 are preferably slightly wider
than the width of the portions of members 102 that are disposed in
slots 210. The extra width should be wide enough to permit seating
unit 114 to be coupled to units 124 and 175 in the manner described
herein (e.g. by being slid into position, lifted, and dropped as
shown in FIG. 15, or pivoted about its front bottom 202 or rear
bottom 200 edges) while at the same time being narrow enough to
hold seating unit 114 in proper front-to-rear alignment with
adjacent seating units 124, 175. Slots 210 should not be so wide
that front 206 of stationary seating unit 114 appears misaligned
(and hence broken) when pushed forward or backward with respect to
seating units 124, 175 to which it is coupled.
[0088] Manufacture and Shipping
[0089] The design of the sofa and the individual seating units
described above provide the manufacturer, the distributor, the
shipping company, the retailer, and the end-user with particular
advantages not provided by any of the multi-unit or multi-seat
sofas disclosed in the prior art. These advantages are due
primarily to the mode in which prior art sofas are packaged,
stored, and shipped.
[0090] Sectional sofas in the prior art are made as individual
seating units that are manufactured on a single assembly line, and
are then bolted together using a long and relatively lightweight
steel bar. Once bolted together, this long single piece sofa is
inserted horizontally into a long, horizontally disposed box or
carton. These boxes, which can be 10-12 feet long, are then picked
up by special lift trucks and are carefully maneuvered through the
factory to a storage area, where they are stored horizontally, with
the sofa assembled and in the same position it will be and when
unpackaged and placed in a room for use.
[0091] Each sofa must be carefully handled, even when it is within
its cardboard box or carton, since the steel bars or channels
coupling the individual seating units are not particularly strong.
In a typical prior art design, the bars or channels extend the
entire length of the sofa. A first bar is bolted to the laterally
extending front edges or front sidewalls of all of the seating
units, and a second bar is bolted to the rear edges or rear
sidewalls of all of the seating units. These bars add considerable
weight to the sofa, yet due to their length are not rigid enough to
prevent the sofa from flexing when it is lifted and carried at each
end.
[0092] Due to their length, each prior art sectional sofa takes up
a significant portion of floor space. A typical prior art sofa
carton is 3 feet wide 3 feet high and 11-12 feet long, for a total
of 33 square feet for each sofa. A further complication is that
only one sofa carton can be placed on each 33 square foot portion
of warehouse space. Sofa cartons cannot be stacked two cartons high
since their weight will rest on the armrests of the sofa underneath
them, supporting the upper sofa at each end. Since the upper sofa
is only supported at each end, a steady bending force is applied to
the upper sofa and the steel bars or channels that couple each of
its seating units together. Over time, the steel bars or channels
will often bend in the middle under this load, sometimes twisting
the motion units. When this happens, the motion units are typically
damaged and do not operate properly. The sofa is a loss.
[0093] Two people are required to deliver a prior art sofa in a
long horizontal sofa carton to a customer's house. With one person
grasping each end of the carton, it is carried into the house,
through doorways, around corners, and upstairs, until they have
carried it to the place where it is to be unpacked. Unfortunately,
during this extended handling the sofa is often bent going around
corners or damaged banging against door trim. The box itself must
typically be removed at the entrance of the house because it is too
big to take through doorways and around corners.
[0094] In contrast to this prior art system, a sofa according to
the present design is significantly stronger than the prior art
sofas. Furthermore, a sofa of the present design can be shipped and
handled much more easily. Furthermore, it can be stored in
warehouses or stockrooms in much greater density, and can be
handled by common, everyday equipment found in shipping and
receiving areas such as large hand trucks. All of these benefits
are due to the particular construction of the sofa, and the fact
that the sofa itself is not assembled at the factory, but is
assembled at its final destination in the customer's dwelling. The
construction of the sofa, in turn, is based upon the novel way of
coupling together the seating units of that sofa.
[0095] Referring now to the improved system of manufacturing,
storing, shipping, and assembling sectional sofas shown in FIGS. 17
and 18, seating units 124, 114 and 175 can be manufactured in
separate manufacturing lines 300, 302, 306. Alternatively the three
seating units can be manufactured in one or two lines as well. The
benefit of manufacturing individual types of seating units in
separate lines is that the manufacture of seating units need not be
entirely stopped whenever one type of seating unit cannot be
manufactured.
[0096] For example, if assembly line 306 runs out of a part needed
for the manufacture of seating unit 175, assembly lines 303, 302
can continue manufacturing seating units 124 and 114. This is
possible because each seating unit is individually packaged in its
own box 308, 310, 312. Since each seating unit is packaged in its
own box, the seating units for a single sofa can be packaged
individually and at different times. They can be stored in a
warehouse in their individual boxes and later brought together and
joined for shipping to a distribution center, retailer, or ultimate
purchaser. In the prior art system, sofas are made one at a time on
a single production line. Should a part be missing for any one of
the seating units, for example, the entire production has to stop.
In the prior art system, in which sofas were manufactured as
complete units, no sofa is complete without the missing parts, and
therefore no sofa can be packaged and stored as long as one seating
unit of that sofa is missing components. All production shuts
down.
[0097] Each individual seating unit 124, 114, 175 is stored in its
own respective carton 308, 310, 312. Typically all three production
lines are run simultaneously, each line producing one style of
seating unit and packaging that unit in its respective carton. The
cartons 308, 310, 312 have visual indicia 314, 316, 318, such as
labels, that include visual markings indicating the model of the
sofa, and visual markings indicating the particular location of the
seating unit within the sofa. For example, indicia 314 might say
"Model 17, left facing armrest", indicia 316 might say "Model 17,
center unit", and indicia 318 might say "Model 17, right facing
armrest", where "Model 17" indicates the model of the sofa and
"left facing armrest", "center unit", and "right facing armrest"
indicate the particular location of a seating unit within the sofa
itself. Other visual indicia may include such things as labels
indicating color, style, fabric, and date of manufacture.
[0098] In the preferred embodiment, the seating units are not
shipped separately to distribution centers, warehouses, or ultimate
consumers. They are preferably shipped as several boxes containing
all the seating units necessary to make a single sofa. In the
example illustrated in FIG. 17, the sofa is made of three seating
units 124, 114, 175. For that reason, FIG. 17 shows three assembly
lines and three individual cartons in which the seating units are
inserted. It should be recognized, however, that any number of
seating units can be coupled together to make a single sofa in
accordance with the present invention. For convenience, however,
the explanation below is limited to a sofa comprised of three
seating units.
[0099] Once seating units 124, 114, 175 have been placed in
cartons, the cartons are preferably joined together and packaged as
a single sofa package 320. In the preferred embodiment, the three
cartons 308, 310, 312 containing seating units 124, 114, 175 are
stacked one on top of the other in vertical alignment with visual
indicia 314, 316, 318 oriented to face the same direction. Once
stacked, the three cartons of seating units are fixed together.
FIG. 17 shows a preferred method of fixing the cartons together.
Plastic film 322 is unrolled from a plastic film roll 324 and is
wrapped around and around the three cartons, joining all three
together as a single sofa package 320.
[0100] Sofa package 320 does not suffer from the same problems as
prior art sofa cartons did because of its vertical orientation when
stored. Sofa package 320 can be stacked vertically to take up a
3.times.3 foot square of floor space and extend 8-10 feet up into
the air. This is a much more efficient use of warehouse space. This
vertical orientation is possible because of the orientation of the
seating units within each carton and the fact that multiple (3 in
this example) cartons are used. The seating units are packaged in
each carton as they would rest on the floor: with their bottom
sides facing downward and their top sides facing upward, as shown
in FIG. 17 and (shown without their cartons) in FIG. 14 herein.
[0101] Since each seating unit is designed to support loads applied
to the seating unit in a vertical direction it can help support the
weight of one or two other seating unit stacked on top of it.
Furthermore, a significant portion of the load is not transmitted
from seating unit to seating unit, but is transferred from the
seating unit carton to the seating unit carton below that and
thence to the ground. Since each seating unit is in a carton, and
each seating unit rests upon a lower surface of its carton, the
orientation of the cartons, one above the other, resting against
each other, transfers a significant portion of the load down the
sidewalls of the cartons to the ground. Only a reduced portion of
the weight is transferred from seating unit to seating unit,
typically by slight downward flexing of the bottom of one carton
against the top of the carton below, which in turn presses
(slightly) against the seating unit in the below carton.
[0102] Once the sofa package 320 is created, it is then carried
(typically by a wheeled vehicle 323) to a warehouse or storage area
325 where it is stored on end in a reduced space. Since the
footprint of the sofa package is only 3'.times.3', wheeled vehicle
323 need not be a custom vehicle capable of lifting and
transporting an 11-12 foot long horizontal package, as the prior
art sofa cartons require. Since it does not need to maneuver with
an 11-12 foot carton extending straight out from vehicle 323, the
warehouse aisles it travels down can be much narrower. Hence,
warehouse space previously devoted to vehicle travel can be reduced
in size. This, in turn, permits the warehouse or storage area to
have even more footage available for storing sofa packages. In
addition, the wheeled vehicle can be as simple as a single hand
truck operable by one individual, such as hand trucks used to lift
and carry refrigerators, ice boxes, and other appliances having a
similar three-foot by three-foot footprint.
[0103] Eventually, the manufacturer receives an order for the sofa
in sofa package 320 and delivers package 320 to a retailer or
distribution center. Wheeled vehicle 323 collects sofa package 320
and places it aboard a vehicle such as truck 326. Truck 326
preferably has an engine and chassis that that support a shipping
container 328. This container is preferably separable from the
engine and chassis. A particular advantage to the arrangement of
the sofa in sofa package 320 is that its height is less than that
of a standard sofa carton set on end. This permits sofa package 320
to be placed in container 328 in the upright orientation shown in
FIG. 17, and not laid on its side, as would be required of a
traditional sectional sofa carton.
[0104] Once sofa carton 320 is loaded, truck 326 continues to ship
330, which is configured to carry container 328 over body of water
332 inside container 328 to the ship's destination.
[0105] When ship 330 arrives at its destination, sofa package 320
is transferred to truck 334 and it is taken to warehouse or
distribution center 333. Truck 334 may be configured to receive and
transport container 328 with sofa package 320 inside, or it may be
configured with its own body 336 which is configured to receive
sofa package 320 when the ship is unloaded at its destination.
[0106] Sofa package 320 is stored at warehouse or distribution
center 333 until an order for the sofa in package 320 is received,
either from a retailer or from an ultimate consumer (i.e. a user)
of the sofa and the final transport step begins.
[0107] Due to the unique construction and packaging of the sofa,
this final transport is preferably performed in two different
ways.
[0108] In accordance with a first method, sofa package 320 is
loaded on a wheeled vehicle 334 which takes it to a loading area
336 at warehouse or distribution center 332. It is then broken down
into three cartons 338, each carton enclosing its own seating unit.
One, two, or all three of these cartons are then loaded into the
vehicle 340 such as a small enclosed truck, pickup truck, or car.
Vehicle 340 then transports these cartons to a dwelling or office
342 where they are unloaded from vehicle 340. More than one trip
may be necessary to take all three cartons to dwelling or office
342. Once unloaded from vehicle 340, the cartons are carried inside
individually and successively to the room in dwelling 342 where the
sofa will be assembled.
[0109] The seating units 124, 114, 175 inside the cartons are then
individually and successively unwrapped (FIG. 14) to expose their
knocked down form for shipping, with their disassembled seat backs
resting horizontally, and facing downward on top of their
corresponding seat portions. At this point, the user lifts up the
seat backs and attaches them to the seat portions of each seating
unit and couples the seat portions together as shown in FIG.
15.
[0110] In the second shipping method, vehicle 334 carries sofa
package 320 to vehicle 344 (typically a delivery truck) in which it
is loaded in the preferred vertical, upstanding position without
separating the three individual cartons. This arrangement saves
floor space and permits several sofas or other items to be loaded
inside vehicle 344 adjacent to sofa package 320.
[0111] Once vehicle 344 has been driven to dwellng 342, sofa
package 320 is removed from the vehicle and broken down into its
separate cartons. Alternatively, sofa package 320 is broken down
into individual cartons inside the vehicle itself and each carton
is removed singly and successively from vehicle 344.
[0112] As in the previous case, the boxes are singly and
successively taken inside dwelling 342 to the room in which the
sofa is to be assembled. Once in the room, the cartons are removed
from each seating unit. With the cartons removed, the three seating
units will appear as shown in FIG. 14. At this point, the user
lifts 6 the seat backs and attaches them to the seat portions of
each seating unit and couples the seat portions together as shown
in FIG. 15.
[0113] There are several advantages to this arrangement. The prior
art sofa packages were typically too tall to be turned on end and
carried in typical delivery trucks (e.g. vehicles 340, 344). By
providing a sofa package with a lower height (in a vertical
orientation) than the standard sofa carton, it is possible to fit
sofas into more vehicles. This permits sofas to be carried in a
greater variety of enclosed (i.e. covered) trucks. Furthermore, by
providing a sofa that is broken down and stored in three individual
cartons, a single person can carry the sofa into a house for
dwelling 342 either by hand or with a hand truck. This, in turn,
permits sofa pickups and deliveries to be made by a single person
driving an automobile or small truck. Vehicles 340, 344 can be
manned and occupied by a single individual who (1) drives the
vehicle to its destination dwelling 342, (2) unloads the vehicle,
(3) successively carries each carton into the dwelling, (4) unwraps
each carton, and (5) assembles the sofa. Since sofa package 320 is
actually comprised of three individual cartons, parts of the sofa
are not lost during shipping since they are not separated. Only
when the sofa is sold and makes its final leg of the delivery, or
alternatively is delivered to its final destination, need the
package be separated. Further, since each individual seating unit
is separately wrapped, each seating unit can be carried, either
wrapped or unwrapped, into dwelling 342 by itself, and not coupled
to the other two seating units. Traditional sofa cartons are
oftentimes so large that the sofa can only be brought inside the
dwelling after the sofa had been completely unwrapped in order to
provide clearance to get through doorways, down halls, and around
corners. By providing individual seating units that are separately
wrapped, the user can take them inside dwelling or office 342 in
their wrapped condition, preventing injury to the seating units
when the cartons inevitably bump against walls, doorways, and other
items.
[0114] It will be understood that changes in the details,
materials, steps, and arrangements of parts which have been
described and illustrated to explain the nature of the invention
will occur to and may be made by those skilled in the art upon a
reading of this disclosure within the principles and scope of the
invention. The foregoing description illustrates the preferred
embodiment of the invention; however, concepts, as based upon the
description, may be employed in other embodiments without departing
from the scope of the invention. Accordingly, the following claims
are intended to protect the invention broadly as well as in the
specific form shown.
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